Recycled waste as air entrainment admixtures

ABSTRACT

Use of waste generated as a byproduct of a first manufacturing process as an air entraining admixture (ABA) in a second product. In some instances, the waste materials can be used as an AEA during cement and/or concrete formation, and may also be waste materials produced during shampoo manufacturing. It is contemplated that the use of non-conventional materials as an AEA conventional applications will often result in products that have performance characteristics similar to conventional AEAs.

This application claims the benefit of U.S. provisional application No.60/379,554, titled “Recycling of Shampoo Wastes” and filed May 7, 2002,incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

The field of the invention is waste recycling and concrete formation.

BACKGROUND OF THE INVENTION

The production of shampoo, body soaps, hair conditioners and similarpersonal care products are an important segment of the health and beautymarket. These products typically consist of water, surfactants,fragrances, and proprietary ingredients, and are ubiquitous throughoutsociety. The manufacture of such products generally requires closequality control procedures, and a high standard of sanitary conditions,similar to that found in the food or pharmaceutical industry.

Many shampoo production facilities manufacture a number of similarproducts, usually in standard, batching operation. When production isswitched between differing varieties it is not uncommon that allequipment must be drained, washed and rinsed. Waste from shampoomanufacturing typically is found in either a concentrated or diluteform. Concentrated shampoo waste (being similar to shampoo products) isgenerally derived from draining of lines, materials not meetingspecifications, dated product, discontinued product, and formulationconstituents. Diluted shampoo waste is generally the “rinse water”generated during formulation change over purging of lines, clean-upoperations, and rinsing of equipment and tanks. The difference in theconcentrated and dilute forms is in the percentage of residual shampooproduct. Rinse waters typically have less than 10%, while concentratedforms of waste will have greater than 10%, and may essentially be 100%shampoo materials.

Disposal of the dilute rinse water is usually via the sanitary sewer,and hence to a Public Owned Treatment Works (POTW). The dilute wastewill have a slightly elevated pH, elevated Biochemical Oxygen Demand(BOD), foam and odor. Large volumes discharged to the sewer system cannegatively impact the POTW, through altering influent pH, creatingexcessive foaming especially in secondary aeration tanks, and consumingtreatment capacity due to increased influent BOD values. These impactsare frequently offset by additional sewering charges paid by thedischarger.

Disposal of the concentrate waste is more problematic, due to a veryhigh pH and constituent concentrations that may exceed sewer dischargestandards at best and hazardous waste definitions frequently. Theconcentrate may also be hazardous due to bioassay assessment. Shampoowaste concentrate is typically collected by the manufacturer and shippedoff-site for disposal/destruction at appropriately permitted facilities.

The costs to the manufacturer for the disposal of both dilute rinsewaste and concentrate waste is significant. Equipment and manufacturingdesigns help assure that, minimal waste production occurs during batchchanging operations, and quality control procedures help minimize thefrequency of out of specification materials. Still, significant volumesof waste material are generated annually.

Portland cement manufacturing is a world wide industry with cement kilnslocated throughout the world. Over 100 million tons of cement isproduced annually. Cement manufacture uses a variety of minerals, whichwhen blended, ground and calcined form a intermediate product known ascement clinker. Calcium aluminum, iron, and silica are the primaryelemental components of cement clinker. Clinker is finely ground with asmall percentage of gypsum-added to produce ordinary portland cement(OPC). Cement specifications designate the chemistry and attributes ofthe cement. Cement, when mixed with water, sand and possibly anaggregate, cures to form a hardened material called concrete. Concretewith no aggregate is often referred to as grout or mortar. The AmericanSociety for Testing and Materials (ASTM) identifies a number of cementtypes, each with a differing set of performance specifications.

Materials added to the OPC during grinding operations or added whenconcrete is being prepared can impart specific characteristics of valueto the builder. One of the functional additions is air entrainingadmixtures (AEA). AEA can be added during the grinding of cementclinker, or added to OPC as part of the concrete recipe. AEA materialsform small air bubbles in the concrete matrix while in the wet stage,which are maintained through hardening and curing. Air entrainedconcrete is superior to concrete formed from OPC for applications wherefrost resistance is important, when used as a mortar, in stucco, orwhere workability is important. Air entrained portland cement is a valueadded material, being sold at prices well above OPC.

Air entrained portland cement and air entrainment admixtures have beenwidely used throughout the cement industry since the early 1950's. Thereare a number of types available commercially, with specific formulationseither patented or proprietary in nature. Materials used as AEAsinclude 1. The salts of wood resins; 2. Synthetic detergents; 3. Saltsof sulfonated lignin; salts of petroleum acids; fatty or resinous acidsand their salts. The manufacture of air entrained portland cement andair entrained concrete is a well known and accepted art.

Air entrainment is measured as a percentage of air in a specificallyprepared mortar sample. Test protocols are well established such as inASTM C185, “Test Method for Air Content in Hydraulic Cement Mortar”. Forreference purposes OPC will often have about 6% air entrained, while anAEA portland cement will often have up to 25% air entrainment. Themanufacture, based on intended use and performance criteria determinesthe percentage of entrained air.

Further information relating to concrete can be found in the work titled“Concrete Materials—Properties, Specifications, and Testing” by SandorPopovics and published by Noyes Publication in 1992 (herein incorporatedby reference in its entirety).

SUMMARY OF THE INVENTION

The present invention is directed to the use of waste generated as abyproduct of a first manufacturing process as an air entrainingadmixture (AEA) in a second product. In some instances, the wastematerials can be used as an AEA during cement and/or concrete formation,and may also be waste materials produced during shampoo manufacturing.It is contemplated that the use of non-conventional materials as an AEAin conventional applications will often result in products that haveperformance characteristics similar to conventional AEAs.

Various objects, features, aspects and advantages of the presentinvention will become more apparent from the following detaileddescription of preferred embodiments of the invention, along with theaccompanying drawings in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram of a first method embodying the invention.

DETAILED DESCRIPTION

Referring to FIG. 1, a method 100 of recycling waste comprises: step110, obtaining a waste material resulting from the manufacture of afirst product; and step 120, utilizing the obtained waste material as anair entraining admixture in the production of a second product.

First Product

The first product could be any product for which waste material isgenerated during the product's production. However, it is contemplatedthat the waste material may be more likely to be suitable as an AEA forproducts that are soaps or shampoos for personal use. The phrase “forpersonal use” as used herein indicates that the use relates to washing aperson's skin or hair. Shampoos, as the term is used herein, include anyof various liquid or cream preparations of soap or detergent used towash the hair and scalp (i.e. for personal use), and any of variouscleaning agents for rugs, upholstery, or cars. Other products that arecontemplated to involve waste materials suitable as AEAs include wasteresiduals from the manufacture of soaps, detergents, and similarproducts, even if the products are not designed, for personal use. Assuch, production of products like dish washer soaps, laundry detergents,and rug cleaners may generate waste materials suitable as AEAs. It isalso contemplated that any product containing a foaming agent may besuitable as waste material generated during production of such productswill likely also contain a foaming agent and be particularly well suitedfor use as an AEA.

Waste Material

The waste material may be any material that is a byproduct of theproduction of the first product and is also suitable for use as an AEAin producing a second product. It is contemplated that the wastematerials suitable for use as ABAs will include quantities of the firstproduct that failed to meet required specifications, have aged beyondtheir useful life, or that are no longer being offered for sale. It isalso contemplated that the waste materials suitable for ABAs may alsoinclude quantities of the first product or components of the firstproduct that are mixed with rinse water used in purging of lines,clean-up operations, and rinsing of equipment and tanks where suchlines, equipment, and tanks are used in the production of the firstproduct.

Other waste materials contemplated a being suitable for AEAs includewaste residuals from the manufacture of soaps and detergents or otherproducts containing a foaming agent.

It is contemplated that the methods disclosed herein will beparticularly advantageous when the waste material has characteristicsthat are problematic when disposing of the material, or characteristicsthat make it particularly suitable for use as an ABA. Some contemplatedcharacteristics include: the waste material being a liquid; the wastematerial having a pH greater than 8.0; the waste material having a BODconcentration greater than 1000 mg/L; the waste material being likely tocause foaming in aeration tanks of treatment plants; and the wastematerial containing no toxic or regulated compounds.

As previously discussed, waste material comprising soap or shampoo iscontemplated as being particularly suitable for use as an AEA in themethods and materials disclosed herein. It is contemplated that somesuch soaps detergents or shampoos can be characterized as comprisingwater, at least one-surfactant, and at least one fragrance. Other suchsoaps and/or shampoos may be characterized has comprising water at leastone surfactant and sodium silicate.

Obtaining the Waste Material

Obtaining the waste material may be accomplished in any manner thatmakes the waste material available for use as an AEA in the productionof a second product. However, it is contemplated that obtaining thewaste material may advantageously comprise one or more of the stepsdescribed in the follow paragraphs.

One method of obtaining waste material is simply to acquire quantitiesof the first product that fail to meet required specifications, haveaged beyond their useful life, or that are no longer being offered forsale. Instead of simply disposing of such product, it is gathered,transported and used as an AEA. Prior to its use it may be subjected toadditional processing steps to place it in a form more suitable for useas an AEA in the production of the second product.

Another method of accumulating waste shampoo, soaps, or detergents isremoval of residuals from storage containers, mixing vessels, conduits,or pipes. Such materials are available during formulation change overswhen multiple products are produced using the same formulation equipmentlines. A more dilute product can be obtained from accumulation of rinsewaters used to clean the formulation equipment.

It is contemplated that obtaining waste materials comprising detergents,soaps, dish washers cleaning solutions or dish detergents will ofteninvolve similar accumulation schemes.

Second Product

The second product may be any product during the production of which thewaste material can be used as an ABA. It's important to note that theuse of the waste material as an ABA need not actually have a positiveimpact on the second product as disposal of the waste material byincluding it in'the second product maybe the only desired benefit.However, it is contemplated that many products will actually benefitfrom including of waste material as an AEA. Such products include,portland cement, concrete and products derived concrete, precastconcrete objects concrete designed for cold climate exposures, stucco,mortars and grouts.

Utilizing the Waste Materials during Production of the Second Product

The actual method of using the waster material as an AEA in theproduction of the second product will vary between embodiments,primarily in relation to differences in the, second product beingproduced. As such, if the second product is cement, the AFA may beincorporated during, formation of the clinker, possibly during grindingof the clinker. When concentrated shampoo waste is used in theproduction of cement by including it during the grinding of cementclinker, addition rates will typically be 0.05% to 0.75% on aweight-to-weight basis with the clinker. The resultant cement will havean air entraining feature, be a dry powder similar in look to OPC or anyother air entraining portland cement. It should be noted that additionrates are based in part on performance requirements of the finishedproduct and thus actual addition rates will likely vary.

Alternatively, if the AEA is to be incorporated in concrete, it willtypically be added as part of the batch operation where the sand,aggregate, portland cement and water are mixed to form wet concrete,which is placed and allowed to harden. The shampoo waste may be added tothe make-up water, or added directly into the mixture during mixingoperations. When concentrated shampoo waste is used in the production ofconcrete, it is preferred that the waste be added at a rate of 0.05% to3.0% on a weight-to-weight basis with the portland cement used in theconcrete. When diluted shampoo waste (i.e. rinse water) is used in theproduction of concrete, it is preferred that the waste comprise 3% to20% on a volumetric basis of the concrete mixture. Dilute shampoo rinsewaste may also or alternatively be added to the mix water or replace themix water.

If the second product is concrete and products derived concrete, precastconcrete objects, concrete designed for cold climate exposures, stucco,mortars and grouts, it is contemplated that the dilute waste materialwill be used as a portion of the make-up water for the second product.

Characteristics of Products Produced using the Methods Herein

It is contemplated that use of the methods herein may be advantageouslyapplied to produce a product that can be characterized as being one ormore of the following:

-   -   (a) an air entrained cement comprising a waste material        generated during the manufacture of a first product as an air        entraining admixture, possibly having the amount of waste        material be 0.05% to 0.75% of the amount of cement clinker on a        weight to weight basis of the cement;    -   (b) a concrete comprising a waste material generated during the        manufacture of a first product as an air entraining admixture,        possibly having the amount of waste materials be 0.05% to 3% of        the amount of cement on a weight-to-weight basis used in the        concrete, or possibly having the amount of waste materials be 3%        to 20% of the amount of cement on a weight-to-weight basis used        in the concrete;    -   (c) a cement comprising calcined shampoo waste;    -   (d) a concrete comprising shampoo waste; and    -   (e) a structure comprising the any of the cements or concretes        described above.

EXAMPLE 1 Utilizing Concentrated Shampoo Waste in Production of Cement

In one instance, a quantity of shampoo waste was obtained and used inthe following manner: A quantity of air entrained plastic type ofportland cement was manufactured by intergrinding 5000 gallons ofshampoo waste into 7000 tons of portland cement clinker, modified tomeet specifications for plastic cement. The manufactured cement (secondproduct) was sold in bagged and bulk form.

EXAMPLE 2 Utilizing Dilute Shampoo Waste in Production of Concrete

In another instance, it is contemplated that a quantity of diluteshampoo waste may be obtained and used in the following manner: 180gallons of the dilute waste would be added to 643 pounds of ordinaryportland cement. To the mixture would be added 1707 pounds of coarseaggregate (2-3% moisture content) and 1310 pounds of sand (6% moisturecontent). The resultant one cubic yard of concrete (second product)would have superior freeze thaw performance attributes.

Thus, specific embodiments and applications of recycled waste as airentraining admixtures have been disclosed. It should be apparent,however, to those skilled in the art that many more modificationsbesides those already described are possible without departing from theinventive concepts herein. The inventive subject matter, therefore, isnot to be restricted except in the spirit of the appended claims.Moreover, in interpreting both the specification and the claims, allterms should be interpreted in the broadest possible manner consistentwith the context. In particular, the terms “comprises” and “comprising”should be interpreted as referring to elements, components, or steps ina non-exclusive manner, indicating that the referenced elements,components, or steps may be present, or utilized, or combined with otherelements, components, or steps that are not expressly referenced.

1. A method of recycling waste comprising: obtaining a liquid wastematerial resulting from the manufacture of a first product; andutilizing the obtained liquid waste material as an air entrancingadmixtuture in the production of a second product.
 2. The method ofclaim 1 wherein te waste material has a pH greater than 8.0.
 3. Themethod of claim 1 wherein the waste material has a BOD greater than 1000mg/L.
 4. The method of claim 1 wherein the waste material compriseswater, at least one surfactant, and at least one fragrance.
 5. Themethod of claim 1 wherein the waste material causes foaming in aerationtans of treatment plants.
 6. The method of claim 1 wherein the wastematerial is a soap or shampoo.
 7. The method of claim 1 wherein thefirst product is a soap or shampoo.
 8. The method of claim 1 wherein thefirst product is a product adapted to be used to wash a person's skin orhair.
 9. The method of claim 1 wherein the second product comprisescement, and the waste material is used in formation of at least some ofthe clinker used in th cement.
 10. The method of claim 10 wherein thewaste is added during fish grinding of the clinker.
 11. The method ofclaim 1 wherein the second product comprises concrete, and the wastematerial is mixed with cement and water to form the concrete.
 12. Themethod of claim 1 wherein the second product comprises concrete, andsubstantially all of the water in the concrete is water from the wastematerial.
 13. The method of claim 1 wherein the waste material comprisesat least one of the following: materials not meeting specifications,expired product, and discontinue product.
 14. The method of claim 1wherein the waste materials comprises rinse water used in purging oflines, clean-up operations, and rinsing of equipment and tanks.
 15. Themethod of claim 1 wherein the method comprises: obtaining a wastematerial resulting from the manufacture of a shampoo, the waste materialcomprising essentially shampoo or diluted shampoo; and utilizing theobtained waste material as an air entraining admixture in the productionof a concrete comprising clinker and water, the waste material beingadded to the concrete as part of the clinker or as an ingredient inaddition to e clinker and water.
 16. A cement product comprising a wastematerial generated during the manufacture of a first product as an airentraining admixture.
 17. The cement product of claim 16, the productcomprising 4 cement wherein the amount of waste material is 0.05% to0.75% of the amount of cement clinker on a weight to weight basis of thecement.
 18. The cement product of claim 16 wherein the cement product isconcrete.
 19. Te concrete of claim 18 wherein the amount of wastematerials is 0.05% to 3% of the amount of cement on a weight-on-weightbasis used in the concrete.
 20. The concrete of claim 18 wherein theamount of waste materials is 5% to 20% of the amount of cement on aweight-to-weight basis used in the concrete.
 21. The cement product ofclaim 16 wherein the cement product is a concrete structure.
 22. Thecement product of claim 16 wherein the cement product is cementcomprising calcined shampoo waste.
 23. The cement product of claim 16wherein the cement product is concrete comprising shampoo waste.